Material Handling Robot Versus Manual Labor and Associated Costs

Article From mhmonline.com
By MHM Staff
February, 2002

Brief Summary:

Businesses considering replacing people with robots have to consider many factors. Robotic systems can remove workers from dangerous environments utilizing them in more productive areas.

When comparing the cost of a material handling robot vs. manual labor, you should consider not just the hourly rate but the total cost of that labor. Your calculation should include workers' compensation insurance, costs of vacations and other benefit packages, turnover, and the associated costs of recruiting and training replacement workers.
You will also want to consider intangible benefits such as the ability to transfer workers out of dangerous/harsh environments and/or drudge work into more pleasant/meaningful assignments.
Some plants have found that by having their robots load/unload from above they were able to eliminate some conveyor sections.
Auto manufacturers have started using some heavier-duty robots now available to load/unload and even manipulate engine blocks.
If your company has never purchased a new robot due to the high initial cost, consider either buying a used one or leasing.
Doesn't used mean abused? Not necessarily. Present-day robot arms are robust. Heavy-duty robots in production applications frequently go 50,000 hours between major overhauls.
Robo-Pall is an integrated system to automatically build, stage and stretch wrap pallets for inbound storage or outbound shipments. The robotic system will build pallets with the same size cases, with individual layers of the same size case, and with many different sizes and weights of cases. Cases can be delivered by conveyor from a pick line, cross dock or reserve storage system. Systems can control and apply labeling, and ID and manifest pallet contents. It operates at eight seconds per case.
This robotic order picking system was installed in a beverage distribution facility to pick layers of containerized products and build mixed pallet loads to be placed on delivery trucks
FANUC Robotics' M-410iWW robot does layer palletizing of products such as beverage trays, bricks/tiles, building material, steel and bundle wire. The system can operate at up to 760 cycles-per-hour with a 1,000-pound payload capacity, depending on the product mix and the end-of-arm tooling.

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